Small Innovation and Big Progress: Guoxing Optoelectronics's "Innovation and Light" series

In the roar of machines in the workshop, there is a smart code to reduce costs and increase efficiency. This issue of Guoxing Optoelectronics FAITH Juzhi·Innovation Youguang series of reports takes you into the production lines of crystal solidification and wire welding. There are no earth-shaking technological breakthroughs here, but there are craft experts who are staring at old problems with real tenacity: from every shutdown and washing of the pulp plate, to every delicate auxiliary material in the refrigerator, to every gold thread on the welding line, they use micro-improvement to solve big problems, allowing every bit of wisdom to converge into the company's competitiveness. Light.​

Pulp tray life revolution: From 36 hours to 60 hours, one less stop on the production line is a benefit

In the crystal bonding workshop of Guoxing Optoelectronics, the slurry tray and the slurry scraper are old partners that have been cooperating for many years. The former holds the adhesive, and the latter is responsible for uniform scraping. Only when the two work together can the crystal bonding machine accurately complete chip bonding. But this pair of partners has long caused headaches for operators: due to the limitations of the traditional structure, the pulp tray will accumulate due to slurry residues every 36 hours of operation, and the entire production line has to be shut down. Employees disassemble and wash the pulp tray and re-debug the equipment., not only disrupts the production rhythm, but also leads to serious waste of adhesive due to frequent cleaning, which has become a stumbling block to reduce costs and increase efficiency.​

Can you let the paddle pan run for a while longer?& rdquo; Zhou Xiaoqiang from the crystal solidification team B of the manufacturing department of the White Light Devices Division led his team to focus on the slurry path inside the slurry tray. They repeatedly disassembled and observed, and found that the slurry flow grooves of the traditional pulp tray were unreasonable, which resulted in the pulp scraper being unable to completely scrape off the residue, which would be blocked over time. In response to this pain point, the team re-planned the groove direction, optimized the slurry flow trajectory, and adjusted the angle and pressure of the slurry scraper to make it fit closer to the surface of the slurry tray and reduce residual accumulation.​

How effective is the improvement? The team selected three core models of adhesives and conducted continuous testing on 79 die bonders: the pulp trays that had been on strike in the past 36 hours can now run stably for 60 hours before being cleaned, and the shutdown frequency was reduced by 40%. What is even more surprising is that the consumption of adhesives has been reduced visually. Monthly consumption has dropped from the previous 15,000 grams to 9000 grams, a sharp drop of 6000 grams. Based on market prices, this is equivalent to saving the company 360,000 yuan in annual costs, equivalent to the total monthly salary of 12 front-line employees.​

When we deal with pulp trays every day, we know best where we are stuck.& rdquo; Project leader Zhou Xiaoqiang said that improvements do not require complex technology, but just observe and ponder more, turning the pain point of shutdown into a highlight of battery life." rdquo;​

[Innovation Team] Person in charge: Zhou Xiaoqiang; Members: Shao Feiyan, Li Junqing, Qian Limei, etc.

Refrigerator smart bodyguard: -20℃ protection makes 150,000 auxiliary materials no longer silently scrapped

In the corner of the crystal solidification workshop, in several inconspicuous refrigerators, there are hidden precious bumps of the production line and adhesive used for chip bonding. These auxiliary materials are extremely sensitive to temperature and must always be in a low temperature environment of- 20 ° C. Once the temperature rises, not only will the viscosity fail, but also cause quality hazards. More importantly, at full production, the value of adhesive in a single refrigerator exceeds 150,000 yuan, comparable to a family car. However, traditional refrigerators do not have a safety warning function: if the power is suddenly cut off at night or during holidays, employees will wait until the next day when they go to work. I found that the whole box of adhesive had long deteriorated, and not only suffered heavy losses, it would also lead to material loss in subsequent production.​

We must not let hidden risks destroy the benefits we have earned so hard.& rdquo; Mo Huixin from the crystal stabilization team of Geely Base led his team and came up with a remote monitoring solution: install a power-off sensing module for each refrigerator, and then connect to the self-developed Weixin Mini Programs Employees don't have to stay next to the refrigerator. Click on their mobile phones to check the temperature in real time; once a power outage occurs, the system will immediately activate triple alarms: the buzzer in the workshop rings on site, the Mini programs pops up a red pop-up window, and the person in charge will also receive text messages and phone reminders to ensure that someone is present within 10 minutes.​

After the safety guard system was implemented, it quickly withstood the test: on a weekend night, the refrigerator in a certain workshop suddenly lost power. The operator who was resting at home received an alarm and rushed to the scene to restart the equipment within half an hour, avoiding 120,000 yuan adhesive scrapping. Today, the system has been fully applied to auxiliary refrigerators in various production processes of Guoxing Optoelectronics, completely eliminating the hidden danger of power failure and damage to materials. Mo Huixin said: The safety of auxiliary materials is the bottom line for production stability. What we do is to turn passive remedies into active protection. rdquo;​

[Innovation Team] Person in charge: Mo Huixin; Members: Luo Jun, Liang Yongkang, Wang Lixiang, etc.

Wire welding saves gold: During the rising gold price period, the optimization of a gold thread saves 800,000 yuan

Since the beginning of this year, the international gold price has continued to rise, exceeding 450 yuan per gram. However, the wire bonding process of Guoxing Optoelectronics RGB devices requires a large number of gold wires to be used every day. In order to ensure the firmness of the solder joints, it is necessary to switch repeatedly. Switching equipment parameters is not only cumbersome to operate, but also causes unnecessary loss of gold wires during the switching process. Every gold wire is wasted, it increases costs.​

Three leaders of the RS manufacturing team of the RGB Device Division, Chen Yinfang, Jiang Shangfeng, and Chen Xueli, led the team in the workshop: they disassembled the wire bonding process, recorded the time and gold wire consumption of each parameter switch, and found that 2 of them can be merged, and 3 parameter adjustments can be simplified. After many tests, the team optimized the arrangement order of solder joints, reduced the number of parameter switching, and adjusted the tension control of the gold wire to make the gold wire more accurate during welding and avoid excessive winding.​

This light-fitting improvement has immediate results: since its implementation in the first half of the year, the consumption of gold thread on a single production line has dropped by 12% year-on-year, and the cumulative savings of gold thread have reached 800,000 yuan based on cost. More importantly, the welding reliability of the product after process optimization did not decrease at all, but the yield rate feedback from customers increased by 0.5%.& ldquo; Saving money is not about cutting corners, but about using every gold thread on the blade." rdquo; Chen Yinfang said that this process has been promoted in the entire range of RGB device products, and it is expected to save more than 1.6 million yuan in costs throughout the year.​

[Innovation Team] Responsible persons: Chen Yinfang, Jiang Shangfeng, Chen Xueli; Members: Chen Junfan, Liang Tianpei, Yang Huajun, Huang Rongzhi, etc.

From extending the battery life of the pulp tray for 24 hours, to installing smart alarms in the refrigerator, to saving every gold thread in the wire bonding process, the front-line craftsmen of Guoxing Optoelectronics use their insights rooted in the scene and tenacity to the end to improve production. Small troubles have become a major breakthrough in reducing costs and increasing efficiency. These innovations may not have dazzling technical labels, but they contain the most solid confidence for enterprise development: when every employee becomes the protagonist of innovation, a little bit of wisdom can gather into a powerful force to push the enterprise forward.​